How SAF, P3, FDM, PolyJet technology transformed the education of students interested in electric vehicle production.
The electric vehicle research group R2X (Run to Xtreme), affiliated with the Department of Mechanical Engineering at Dankook University, is—true to its name—racing toward the extreme. It is a hub where passionate engineers come together to research, design, and develop next-generation electric vehicle technologies.
Founded in 2002, R2X currently has about 52 students actively participating. The team has consistently competed in the electric vehicle category of the university student self-made car competition (Formula Student), organized by the Korean Society of Automotive Engineers (KSAE), and has established itself as a strong contender in domestic university motorsports through innovative technology and outstanding results. In the 2024 competition, we achieved the remarkable feat of winning the Encouragement Award in the E-Formula category with our self-built electric formula vehicle.
R2X designs and manufactures key components that are directly related to vehicle performance. This process is a long and arduous journey. Processing fiberglass or carbon composites by hand requires a great deal of time and effort before the actual parts can be produced. For a student club operating with limited time and manpower, relying on manual labor makes it difficult to allocate resources to design changes or improvements that could lead to better outcomes.
The limitations of implementation are also clear. With conventional processing methods, it is nearly impossible to manufacture parts with complex, streamlined shapes or internal structures optimized for aerodynamics. As a result, engineers often have to settle for designs that are feasible to manufacture, rather than those that maximize performance. This acts as an invisible barrier that hinders the team’s creativity and innovation. Refusing to accept these limitations as inevitable, R2X is tackling the challenge head-on with 3D printing—a new manufacturing paradigm that enables the creation of faster, lighter, and more efficient vehicles.
The journey of introducing 3D printing in R2X represents significant shift in engineering strategy—one that goes beyond simply adopting new equipment. R2X established an engineering strategy focused on applying the right solution for each problem, rather than relying on a single technology or tool for everything. I carefully examined Stratasys’ 3D printer lineup. And after completing the preliminary review, R2X strategically selected and utilized four core technologies—SAF, P3, FDM, and PolyJet—to meet the requirements of key components.
The introduction of Stratasys 3D printing solutions brought more than just a change in how parts are made for R2X—it was a true innovation. First, the development workflow was simplified. As the time and effort previously required for producing battery cooling ducts or performing post-processing were eliminated, team members were freed from repetitive tasks. The valuable time and resources secured through this process can now be invested in high-value activities such as design, simulation, and data analysis. This can be considered an irreplaceable competitive advantage for student teams that must maximize efficiency with limited resources.
The resulting improvement in vehicle performance is an unprecedented achievement. The cooling duct produced with SAF technology prevents battery overheating and maintains stable output, while the ergonomic handle grip created with P3 technology reduces driver fatigue and contributes to shorter lap times. The enclosure, integrally manufactured using FDM technology, increases body rigidity and reduces weight, improving motion performance, while the exterior parts produced with PolyJet technology enhance the vehicle’s overall quality.
The collaboration between R2X at Dankook University and Stratasys clearly demonstrates how 3D printing technology can transform the landscape of next-generation electric vehicles. R2X has gone beyond the limits of conventional manufacturing by leveraging Stratasys’ diverse technology platforms to turn bold, imaginative designs into reality and push vehicle performance to the limit—achieving success in competition. And R2X’s challenge doesn’t end here. Chairman Hyun Ye-chan stated, “Together with my team members, we will continue to push toward the extreme, as the name suggests,” revealing his aspirations for the future.
